Pile cutting system

ABSTRACT

Some embodiments include an apparatus for cutting a pile. In some embodiments, the apparatus includes a shaft module including a cylindrical shaft including a first cavity configured to receive the pile. In some embodiments, the apparatus also includes a cutting module coupled to the shaft module, the cutting module including a second cavity configured to receive the pile, clamps configured to clamp onto the pile, and a saw configured to cut the pile. In some embodiments, the apparatus also includes a drilling module coupled to the cutting module, the drilling module including blades to burrow into an earth surface.

RELATED APPLICATIONS

This application claims the priority benefit of U.S. application Ser.No. 62/189,594 filed Jul. 7, 2015.

LIMITED COPYRIGHT WAIVER

A portion of the disclosure of this patent document contains materialwhich is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patentdisclosure, as it appears in the Patent and Trademark Office patentfiles or records, but otherwise reserves all copyright rightswhatsoever. Copyright 2015, Nabil Mimouni and Ronnie Wayne Wills II.

FIELD

Embodiments of the inventive subject matter relate generally to thefield of cutting systems and more particularly to the field of pilecutting systems.

BACKGROUND

Various industrial structures (e.g., offshore oil platforms) and otherlarge-scale buildings (e.g., bridges, waterfront buildings, etc.) areoften deployed in maritime environments. When deployed in maritimeenvironments, these structures may be supported by piles (e.g., concretepiles, steel piles, composite piles, etc.) that extend deep in theseafloor. Over time, these structures and buildings may bedecommissioned or otherwise taken out of use. After a structure isdecommissioned, various governmental regulations may govern how thestructure must be removed from a maritime environment. For example,after an oil production platform is decommissioned, federal regulationsmay require that the platform, including its concrete piles in theseafloor, be removed from the sea. In some instances, the regulationsmay mandate that the piles be removed down to a certain depth, such asfifteen feet below the sea floor.

Current technology for removing sea-based piles often utilizes blastingmaterial to blast away the seafloor, exposing the buried piles (e.g., upto 15 feet below the seafloor). After each pile is exposed via blasting,workers (e.g., using robots) may saw-off a portion of the pile, and burythe remainder of the pile. As a result, only a portion of the pileremains beneath the seafloor.

One problem with the above-noted technique is that under-sea blastingmay destroy marine wildlife. To protect marine wildlife, governmentregulations may prohibit blasting when certain marine wildlife is inproximity. To comply with these regulations, workers must ceaseoperations until the specific wildlife is sufficiently distant from theblasting. As workers and equipment sit idle, costs may significantlyincrease, rendering the removal process unfeasible.

SUMMARY

In some embodiments, an apparatus for cutting a pile comprises a shaftmodule including a cylindrical shaft including a first cavity configuredto receive the pile, a cutting module coupled to the shaft module. Thecutting module includes a second cavity configured to receive the pile,clamps configured to clamp onto the pile, and a saw configured to cutthe pile. The apparatus also includes a drilling module coupled to thecutting module, the drilling module including blades to burrow into anearth surface.

In some embodiments, the saw includes a diamond wire blade.

In some embodiments, the blades are helically shaped, and wherein theblades are mounted on an external surface of the drilling module.

In some embodiments, the shaft module is configured to couple to a drivemechanism configured to provide a rotational force for rotating theapparatus.

In some embodiments, the rotational force to cause the blades to burrowinto the earth surface.

In some embodiments, the shaft module includes a motor configured toprovide a rotational force to spin the apparatus and cause the blades toburrow into the earth surface.

In some embodiments, a method for cutting a pile lodged into a seafloorsurface includes lowering a pile cutting apparatus around a pile,wherein the pile cutting apparatus envelops the pile. The method alsoincludes spinning the pile cutting apparatus around the pile to burrowthe pile cutting apparatus into the seafloor surface. The method alsoincludes clamping the pile cutting apparatus to the pile via clampscontained in the pile cutting apparatus. The method also includescutting the pile using a saw included inside the pile cutting apparatus,and lifting a portion of the pile and the pile cutting apparatus awayfrom the seafloor surface.

In some embodiments, the portion of the pile resides at least partiallybelow the seafloor surface.

In some embodiments, wherein the spinning results from a rotationalforce applied, on the pile cutting apparatus, from a motor residing on aboat.

In some embodiments, the spinning results from a rotational forceoriginating in the pile cutting apparatus.

In some embodiments, the pile cutting apparatus includes a drillingmodule including helical blades configured to burrow into the seafloorsurface.

In some embodiments, the cutting is performed by a cutting moduleincluding a saw motor, cutting wire, and pulleys configured to maintaintension in the cutting wire as the cutting wire passes through the pile.

In some embodiments, an apparatus for removing a portion of a pile thatis lodged in a seafloor includes a drilling module configured to envelopthe pile and drill into the seafloor by rotating around the pile. Theapparatus also includes a cutting module coupled to the drilling moduleand configured to envelop the pile. The cutting module includes a sawconfigured to cut-off the portion of the pile.

In some embodiments, the drilling module includes helical blades mountedon an outer surface of the drilling module.

In some embodiments, the cutting module includes a lower rotating ring,a middle rotating ring, and an upper rotating ring in a stack, whereineach rotating ring includes a first tab, second tab, and a mobile pulleymounted on the second tab.

In some embodiments, a saw wire rides on the mobile pulleys that aremounted on the lower rotating ring, middle rotating ring, and upperrotating ring.

In some embodiments, rotation of the lower rotating ring causes thesecond tab of the lower rotating ring to engage the first tab of themiddle rotating ring causing rotation of the middle rotating ring.

In some embodiments, rotation of the lower rotating ring and middlerotating ring will cause the wire saw to cut the pile.

In some embodiments, the apparatus further comprises a shaft modulecoupled to the cutting module, and configured to envelop the pile, theshaft module including a motor configured to apply a rotational force tothe drilling module to drill into the seafloor.

In some embodiments, the motor includes a motor gear configured to drivespur gears, wherein the spur gears are configured to drive an internalgear configured to spin the apparatus.

In some embodiments, the drilling module includes a clamp configured tohold the apparatus fast to the pile, after drilling into the seafloor.

BRIEF DESCRIPTION OF THE FIGURES

The present invention is illustrated by way of example and notlimitation in the Figures of the accompanying drawings in which:

FIG. 1 is a perspective view of an embodiment of the cylindricalapparatus 102 being deployed from a boat.

FIG. 2 is a perspective view of the cylindrical apparatus 102 envelopingthe pile 106.

FIG. 3 is a perspective view of the cylindrical apparatus 102 carryingthe pile 106 to the sea surface.

FIG. 4 is a perspective view of an pile removing apparatus, according tosome embodiments of the inventive subject matter.

FIG. 5 is an exploded view of portions of an pile removing apparatus,according to some embodiments of the inventive subject matter.

FIG. 6 is a partial side view of a drilling module 600, according tosome embodiments.

FIG. 7 is a top view of a drilling module 700.

FIG. 8 is an exploded view of a drilling module 800.

FIG. 9 is a perspective view of a connecting plate 900 of a drillingmodule.

FIG. 10A is a side view of a helical blade of a drilling module.

FIG. 10B is top view of the helical blade of the drilling module.

FIG. 10C is a side view of an inner blade of a drilling module.

FIG. 11A is a perspective view of a drilling module's helical bladeincluding a plurality of claws, according to some embodiments.

FIG. 11B is a top view of a claw, according to some embodiments.

FIG. 12A is a side view of a drilling module 1200.

FIG. 12B shows the drilling module 1200 without the helical blades.

FIG. 13 is an exploded view of a drive module, according to embodimentsof the inventive subject matter.

FIG. 14 is a perspective view of a cutting module of an embodiment ofthe pile removing apparatus.

FIG. 15 is a perspective view of components of a cutting module.

FIG. 16 shows another perspective view of a cutting module components1500.

FIG. 17 shows a perspective view of the pile cutting apparatus of FIG.1.

FIG. 18 shows a perspective view of certain components of a pileremoving apparatus 1800, according to some embodiments of the inventivesubject matter.

FIG. 19 shows an exploded view of certain components of a pile removingapparatus 1900.

FIG. 20 shows the cutting module with top cover lifted.

FIG. 21 shows components of a cutting module, according to someembodiments of the inventive subject matter.

FIG. 22 is an exploded view of components of a cutting module, accordingto some embodiments of the inventive subject matter.

FIG. 23 is another perspective view of components a cutting module,according to some embodiments of the inventive subject matter.

FIG. 24 is an exploded view of a pile removing apparatus including itsown motor for drilling into the earth.

FIG. 25 is a perspective view of carriage 2500, according to someembodiments of the inventive subject matter.

FIG. 26 is an exploded view of a drilling apparatus mechanism, accordingto some embodiments of the inventive subject matter.

FIG. 27 is a perspective view of a pile removing apparatus, according tosome embodiments of the inventive subject matter.

FIG. 28 is an exploded view of a pile removing apparatus, according tosome embodiments of the inventive subject matter.

FIG. 29 shows a perspective view of a clamping mechanism, according someembodiments of the inventive subject matter.

DESCRIPTION OF THE EMBODIMENTS Introduction

Embodiments of the inventive subject matter include techniques andequipment for removing piles and other structures from the seafloor.This description uses the terms pile removing apparatus and pile cuttingapparatus synonymously.

Some embodiments include a cylindrical pile removing apparatus deployedfrom a boat into the sea. FIG. 1 is a perspective view of an embodimentof the pile removing apparatus 102 being deployed from a boat. The pileremoving apparatus may be connected, by a drive shaft 104, to arotational power source residing on the boat (not shown). Alternatively,the pile removing apparatus may include its own rotating power source.In either case, an operator can lower the apparatus 102 over (i.e.,enveloping) a pile 106. In some instances, the operator lowers theapparatus 102 until the apparatus contacts the seafloor. At this point,the cylindrical apparatus 102 envelops a portion of the pile 106 that isprotruding above the seafloor. The apparatus includes a shaft module108, cutting module 110, and drilling module 112.

In some embodiments in which the rotational force is provided by theapparatus itself, the shaft module 108 includes clamps that telescopeout of the shaft module 108, and clamp onto the pile 106. After theclamps engage the pile, the apparatus can rotate about the pile to drillinto the seafloor.

Powered by the rotational power source, the apparatus 102 burrows intothe seafloor to a suitable depth (see FIG. 2), saws-off a portion of thepile, and carries the portion 302 to the surface (see FIG. 3). A stub304 remains under the seafloor. As a result, the apparatus 102 hasremoved a large portion of the pile (e.g., to a specified depth beneathseafloor) without utilizing blasting material, and with relativelylittle disturbance the marine wildlife.

Description of Embodiments

FIG. 4 is a perspective view of a pile removing apparatus, according tosome embodiments of the inventive subject matter. As shown, the pileremoving apparatus 400 includes three main components—a drive module402, shaft module 404, and drilling module 406. The drive module 402 iscoupled with the shaft module 404 via a connection interface 408 thatmay include fasteners and other suitable coupling devices. The shaftmodule 404 may be similarly connected to the drilling module 406. Asshown, the drive module 402 includes an interface for connecting to adriveshaft and external rotational power source (e.g., electric motor,combustion engine, etc.). Although not shown, the pile removingapparatus 400 includes a cylindrical cavity (inside the modules) forreceiving a pile during the pile removal process. Although someembodiments saw-off pile portions that are taken to the surface in thecavity, other embodiments need not utilize a sawing mechanism. In suchembodiments, the pile removing apparatus 400 burrows to a depth deeperthan the pile, and removes the pile without sawing it. As a result, someembodiments of the pile removing apparatus 400 may not include thecutting components described herein.

FIG. 5 is an exploded view of portions of a pile removing apparatus,according to some embodiments of the inventive subject matter. FIG. 5shows portions of a pile removing apparatus 500, including a shaftmodule 502, cutting module 504, and drilling module 506. The shaftmodule 502 and drilling module 506 may be similar to those shown in FIG.4. In some embodiments, the cutting module 504 is disposed within theshaft module 502. The cutting module 504 may include a cable saw forcutting-off the pile. For example, the cutting module 504 may includemotors that spin a cable, and pull the spinning cable through the pile.In operation, after the pile removing apparatus 500 envelops a pile, thecutting module 504 severs a portion of the pile.

The following discussion of FIGS. 6-12 will provide details aboutembodiments of the drilling module.

FIG. 6 is a side view of a drilling module 600, according to someembodiments. Like all components of the pile removing apparatus, thedrilling module 600 can be any suitable size. In some embodiments, thedrilling module may be 3 to 6 feet in height. The drilling module 600includes connecting plates 602 used for coupling the cutting module 600to a shaft module of the pile removing apparatus. In some embodiments,the drilling module 600 can include an outer pipe 604, and an inner pipe606. For clarity, the drilling module's blades are not shown in FIG. 6.

FIG. 7 is a top view of a drilling module 700. As shown, the drillingmodule 700 includes connecting plates 702 for coupling the drillingmodule 700 to a shaft module of the pile removing apparatus. Thedrilling module 700 also includes helical blades 704, and inner blades706. As the drilling module drills into the seafloor, the helical blades704 and the inner blades 706 move sand and material.

FIG. 8 is an exploded view of a drilling module 800. As shown, thedrilling module 800 includes connecting plates 802 and bolts 805, whichconnect the drilling module 800 to a shaft module of a pile removingapparatus. The connecting plates 802 are coupled to a cylindrical outerpipe 804. The drilling module 800 also includes two steel plates (806and 810) that lay horizontally. The drilling module 800 includes aplurality of vertically oriented steel plates 808. The drilling module800 also includes an inner pipe 812, which is connected to helicalblades 814, and inner blades 816.

FIG. 9 is a perspective view of a connecting plate 900 of a drillingmodule. In some embodiments, the connecting plate 900 is similar to theconnecting plates noted above. As shown, the connecting plate 900includes a hole 902 through which a fastener can couple the connectingplate 902 to a shaft module of a pile removing apparatus.

FIG. 10A is a side view of a helical blade of a drilling module. FIG.10B is top view of the helical blade of the drilling module. FIG. 10C isa side view of an inner blade of a drilling module.

FIG. 11A is a perspective view of a drilling module's helical bladeincluding a plurality of claws, according to some embodiments. As shown,in some embodiments, the helical blades can include claws 1102. In someinstances, the claws may be oriented in a plane perpendicular to theblade surface. In other instances, the claws can be oriented in anysuitable plane relative to the blade surface. FIG. 11B is a side view ofa claw, according to some embodiments.

FIG. 12A is a side view of a drilling module 1200. The drilling module1200 can include an outer pipe 1202. The drilling module 1200 can alsoinclude a metal plate 1204 oriented at 45° relative to the outer pipe1202. The drilling module 1200 also includes an inner pipe 1206. Theinner pipe 1206 may have the same orientation as the outer pipe 1202. Asshown, the outer pipe 1202 connects to the metal plate 1204, whichconnects to the inner pipe 1206. In some embodiments, instead of themetal plate 1204, the drilling module 1200 includes a resin fill thatconnects the inner and outer pipes. The drilling module 1200 alsoincludes helical blades 1208.

FIG. 12 B shows the drilling module 1200 without the helical blades. Asnoted, the metal plate 1204 can be oriented at 45° angle relative to theouter and inner pipes (1202 and 1206).

The following discussion will turn to embodiments of the drive module.

FIG. 13 is an exploded view of a drive module, according to embodimentsof the inventive subject matter. As shown, the drive module 1300includes a kelly bar sleeve 1302. Drive module 1300 also includes acircular top plate 1304, which includes a plurality of circular holes,and a square hole for receiving the kelly bar plate 1302. The drivemodule 1300 also includes a plurality of rectangular flat plates 1306,which are oriented perpendicularly to the circular plate 1304.Additionally, the drive module 1300 includes a top module shaft 1308.The top module shaft 1308 includes nuts 1310 coupled to an insidesurface of the top module shaft 1304. In some embodiments, the nuts 1310are welded inside the top module shaft, forming a ring pattern. As notedabove, the drive module 1300 can connect to a drive shaft or other powersource that provides a rotational force to spin the pile removingapparatus and drill into the Earth.

FIG. 14 is a perspective view of a cutting module of an embodiment ofthe pile removing apparatus. In FIG. 14, the cutting module 1400includes a protective housing comprising rings 1402 and plates 1404. Therings and plates can be made of steel or any other suitable material.Inside the housing, the cutting module includes components forcutting-off piles and other structures.

FIG. 15 is a perspective view of components of a cutting module. In someembodiments, some of the components are contained within a protectivehousing (e.g., see FIG. 14). In FIG. 15, the components 1500 include asupport ring 1502, which supports concentric annular gears 1504. Theconcentric annular gears may include teeth that engage one or moremotors that rotate the concentric annular gears 1504. In one embodiment,a motor 1510 rotates the concentric annular gears 1504 as part of aprocess for cutting a pile. The cutting process may entail pulling adiamond cable 1508 into contact with a concrete pile. The motor 1510rotates the concentric annular 1504, causing a pulley 1512 (mounted onthe gears) to draw the diamond cable 1504 into contact with the pile. Adiamond cable motor 1506 rotates the diamond cable 1508 at a speedsuitable for cutting the pile.

As shown, the diamond cable 1508 is also supported by fixed pulleys1514.

FIG. 16 shows another perspective view of a cutting module components1500.

FIG. 17 shows a perspective view of the pile cutting apparatus ofFIG. 1. In FIG. 17, the pile cutting apparatus includes a drive module108, shaft module 110, and drilling module 112. Clamps 1702 telescopeout of the drive module 108 and clamp onto the pile, enabling the pilecutting apparatus to burrow into the seafloor by rotating about thepile. The clamps 1702 telescope out to the pile, and retract back intothe drive module 108. In FIG. 17, the clamps include hydraulic cylindersthat push arms into contact with a pile. Other embodiments may includeother suitable clamping mechanisms.

FIG. 18 shows a perspective view of certain components of a pileremoving apparatus 1800, according to some embodiments of the inventivesubject matter. In FIG. 18, the components include a shaft module 1802,cutting module 1804, and drilling module 1810. As shown, a cuttingmodule cap 1806 covers the cutting module 1804. The shaft module 1802includes sockets for receiving the cap's connecting arms 1808. The cap1806 protects components (e.g., hydraulic motors, pulleys, cutting wire,etc.) internal to the cutting module 1804.

FIG. 19 shows an exploded view of certain components of a pile removingapparatus 1900. The components include a shaft module 1902, cuttingmodule 1904, and drilling module 1906. As shown, a cutting module cap1908 includes connecting arms 1910 that mate with sockets 1912 in theshaft module 1902, coupling the cutting module 1904 with the shaftmodule 1902.

FIG. 20 shows an exploded view of certain components of a pile removingapparatus. As shown, a cutting module 2002 includes components forsawing piles (e.g., motor, pulleys, etc.). The cutting module 2002 isconfigured to couple with a cutting module cap 2006. The cutting modulecap 2006 includes housings 2008 that slide into shaft module housings(not shown). In some embodiments, a pulley system 2010 telescopesthrough one of the housings 2008, and up into a shaft module (e.g. seesockets 1912 in FIG. 19). The pulley system 2010 includes a verticalpulley support 2016 and a spring 2014 for applying a vertical force to apulley 2012. The pulley 2012 transfers the vertical force to a wire saw(not shown) that is controlled by cutting components in the cuttingmodule 2002 (e.g., motor, pulleys, etc.). That is, the spring 2014maintains tension on the wire saw (not shown) that rides on the pulleysshown in FIG. 21. The components of the cutting module are described inmore detail below.

FIG. 21 shows components of a cutting module, according to someembodiments of the inventive subject matter. As shown, a cutting module2100 includes a base plate 2108 on which cutting module components aremounted. A horizontal guide pulley 2115, vertical guide pulleys 2114,wire engine 2118, chain engine 2119, vertical pulley support 2020, andlimit bumper 2016 are mounted on the base plate 2108. Three rotatingrings are stacked on the base plate 2108, whereby the rotating ringsrotate about the pivoting ring 2109. The rotating rings include a lowerrotating ring 2135, middle rotating ring, and upper rotating ring 2122(see FIG. 22 for an exploded view of rotating rings). Each of therotating rings serves as a mount for one of the mobile pulleys 2112,2130, & 2131. The mobile pulley 2112 is mounted on the lower rotationring 2135. The mobile pulley 2130 is mounted on the middle rotatingring, and the mobile pulley 2131 is mounted on the upper rotating ring2122. In FIG. 21, each of the mobile pulleys 2112, 2130, & 2131 resideson a tab of its respective rotating ring.

During operation, the components shown in FIG. 21 move the wire 2123into contact with a pile (not shown) disposed inside the pivoting ring2109. To move the wire 2123, the chain engine 2119 drives a chain 2113clockwise, causing the lower rotating ring 2122 to rotate clockwiseabout the pivoting ring 2109. As the lower rotating ring rotates, itmoves the mobile pulley 2112 around the circumference of the pivotingring 2109, thereby moving the wire 2123 across the space inside thepivoting ring 2109. Eventually, the lower rotating ring will rotate farenough so its tab (on which mobile pulley 2112 is mounted) engages a tabof the middle rotating ring. By the lower rotating ring tab engaging themiddle rotating ring tab, the chain 2113 can simultaneously rotate boththe lower and middle rotating rings, and thus simultaneously rotate themobile pulleys 2112 & 2130 around the pivot ring 2109. The middlerotating ring includes a tab that engages with the upper rotating ringtab 2124 (after the middle rotating ring has rotated far enough aroundthe pivot ring 2109). When all tabs are engaged, the chain rotates allthree rotating rings and pulleys 2112, 2130, & 2131 until the tab 2124hits the limit bumper 2116, at which point the wire 2123 has passedthrough the pile. As a result, the mobile pulleys 2112, 2130, & 2131rotate on the rotating rings to maintain tension on the wire 2123, asthe wire 2123 cuts through a pile. The rotating rings are contained andstabilized by rotating ring stabilizers 2111. The wire engine 2118 spinsthe wire 2123 at a speed that enables the wire 2123 to cut though thepile. Although some embodiments rotate the rotating rings clockwise,other embodiments may rotate them counterclockwise.

FIG. 22 is an exploded view of components of a cutting module, accordingto some embodiments of the inventive subject matter. FIG. 22 shows howrotating rings can be stacked. As shown, a cutting module 2200 includesa base plate 2202 connected to a pivot ring 2204. A chain mechanism 2206is mounted on the base plate 2202. In some embodiments, three rotatingrings are stacked above the chain mechanism. As shown, the rotatingrings include an upper rotating ring 2222, middle rotating ring 2221,and a lower rotating ring 2210. Each of the rotating rings 2210, 2221, &2222 includes a mobile pulley 2212 mounted on a tab 2208. As describedabove, the mobile pulleys 2212 and rotating rings 2210, 2221, and 2222rotate about the pivot ring 2204 to move a cutting wire (not shown) intocontact with a pile (not shown). The rotating rings 2210, 2221, & 2222can include additional tabs that control rotation about the pivot ring2204, as described above. Although some embodiments utilize threerotating rings, other embodiments may use any suitable number ofrotating rings.

FIG. 23 is another perspective view of components a cutting module,according to some embodiments of the inventive subject matter. In FIG.23, the cutting module 2300 includes a base plate 2308 and pivot ring2309. Riding on the base plate 2308 and rotating around the pivot ring2309 are the upper rotating ring 2322, middle rotating ring 2340, andlower rotating ring 2310.

The cutting module 2300 also includes a chain motor 2319 configured torotate a chain 2313, where rotation of the chain 2313 causes rotation ofa lower rotating ring 2310, middle rotating ring, and upper rotatingring 2322 about the pivot ring 2309. Mobile pulleys 2312 are mounted onthe rotating rings. As the rotating rings rotate, the mobile pulleys2312 move the wire 2323 into contact with a pile disposed inside thering 2309.

The upper rotating ring 2322 includes a tab 2324 configured to engagethe middle rotating ring, as the middle rotating ring 2340 rotatesclockwise about the pivot ring 2309. Once engaged, the rotating ringssimultaneously rotate until contacting a limit bumper 2316. The pulleysmaintain tension on the wire 2323, enabling the wire 2323 to cut a pile.

The vertical guide pulleys 2314 guide the wire 2323 onto the verticalmobile pulley 2317. The vertical guide pulley 2317 moves up-and-down avertical pulley support 2320. In some embodiments, a spring 2325 appliesvertical tension to the vertical guide pulley 2317, moving the verticalguide pulley 2317 up-and-down the support 2320. For example, as themobile pulleys 2312 rotate clockwise about the pivot ring 2309, thevertical guide pulley 2317 moves down the support 2320, and the spring2325 stretches downward toward the base plate 2308. As the mobilepulleys 2312 rotate (counterclockwise) back to their original positions,the spring 2325 pulls the vertical mobile pulley 2317 upward along thesupport 2320.

The pulleys shown in FIGS. 21-23 can be arranged in any suitable fashionthat moves the wire (see 2123) into contact with a pile, and completelythrough the pile.

This description continues with a discussion embodiments that do notrequire an outside rotational force for turning a pile removingapparatus, as it drills into the earth. As described above, someembodiments of the pile removing apparatus are lowered from a boat thatincludes a motor for applying a rotational force to the pile removingapparatus. In contrast to these embodiments, other embodiments call fora mechanism by which the pile removing apparatus itself provides arotational force for drilling into the earth.

FIG. 24 is an exploded view of a pile removing apparatus including itsown motor for drilling into the earth. In FIG. 24, the pile removingapparatus 2400 includes a shaft module 2402, cutting module 2405, anddrilling module 2401. The shaft module 2402 includes a carriage 2408,which includes carriage rings 2410, and carriage supports 2412. Adrilling module 2414 is connected to the carriage supports 2412. Thecarriage 2408, and drilling module 2414 are described in more detailbelow.

FIG. 25 is a perspective view of carriage 2500, according to someembodiments of the inventive subject matter. As shown, the carriage 2500includes carriage rings 2502 and carriage supports 2504. A drillingmechanism 2506 is connected to the carriage supports 2504. The drillingmechanism 2506 includes a drilling motor 2508 which includes a drillinggear that engages spur gears mounted on the bottom side of a motorsupport 2512. The spur gears engage internal gear teeth of an internalgear plate 2514 to spin the carriage 2500, and consequently spin theentire pile removing apparatus. The drilling mechanism 2506 alsoincludes a plurality of hydraulic cylinders 2510 attached on a bottomside of the drilling mechanism 2506. The hydraulic cylinders 2510 areconfigured to engage a pile and hold the drilling mechanism securely tothe pile.

FIG. 26 is an exploded view of a drilling apparatus, according to someembodiments of the inventive subject matter. FIG. 26 shows a drillingapparatus 2600 configured for use in a pile-removal apparatus. Thedrilling apparatus 2600 includes a drilling motor 2624, which includes amounting flange 2604 and a drive gear 2627. The drilling motor 2604 isconfigured for mounting on a motor support 2625. The motor support 2625includes three cylindrical supports 2605 and a motor mount 2603configured to support the drilling motor 2624 via the mounting flange2604.

The motor support 2625 couples with an internal gear plate 2626. Theinternal gear plate 2626 includes internal gear teeth 2606 configured toengage the spur gears 2627, which in turn engage the drive gear 2627. Asthe drive gear 2627 spins, it drives the spur gears 2627, which in turnspin the internal gear plate 2626. As the internal gear 2626 spins, thedrilling apparatus 2600 spins the entire pile-removal apparatus.

As shown, the drilling apparatus 2600 includes a drilling mechanismsupport 2628 configured to support the spur gears 2627, and hold them incontact with the drive gear 2627 and internal gear 2626. As shown, thedrilling mechanism support includes support cylinders 2610, and otherelements that provide structural support. The drilling mechanism support2628 also includes hydraulic cylinders 2629 configured to clamp onto apile. After clamped onto a pile, the motor 2624 can cause the internalgear plate 2626 to spin, thereby spinning the entire pile removingapparatus about the pile—drilling into the earth. That is, after thehydraulic cylinders 2629 clamp to a pile, all components other than theinternal gear 2626 remain stationary, whereas the internal gear 2626(and the rest of the pile removing apparatus) rotates about the pile.

As noted, the embodiments shown in FIGS. 25 and 26 do not require anexternal rotational force to drill the pile removing apparatus into theEarth. In some embodiments, the apparatus itself includes a drillingmechanism that provides such a rotational force.

Any of the motors described herein can be implemented as hydraulicmotors, electrical motors, or any other suitable motor type. Anysuitable materials can be used to implement the components describedherein. For example, the drilling module can be implemented using steelor any other suitable material.

FIG. 27 is a perspective view of a pile removing apparatus, according tosome embodiments of the inventive subject matter. In FIG. 27, the pileremoving apparatus includes a shaft module 2702, cutting module 2704,and drilling module 2706. As shown, the drilling module 2706 and cuttingmodule 2704 include inner rings for receiving piles into the inside ofthe apparatus. In the embodiment shown in FIG. 27, a cylindrical innershield 2710 connects to the top of the shaft module 2702 and to a pivotring (see discussion above) of the cutting module 2704. The inner shield2710 seals-off the cutting module's components from sea water anddebris, as the pile removing apparatus augurs into the seafloor.Stabilization arms 2712 stabilize the inner shield 2710 inside the shaftmodule 2702. After the pile removing apparatus reaches its desired depthin the seafloor, hydraulic cylinders 2714 push the inner shield 2710upward to enable the cutting module's wire saw to move into contact withthe pile. After the inner shield 2710 has moved upward, the cuttingmodule's components are exposed to seawater during pile cutting. Thecutting module 2704 also includes clamps 2708 rotatably anchored to abase plate in the cutting module 2704. After the hydraulic cylinders2714 move the inner shield 2710 upward, the clamps 2708 rotate intocontact with the pile, and securely hold the pile, as the wire saw cutsthe pile.

FIG. 28 is an exploded view of a pile removing apparatus, according tosome embodiments of the inventive subject matter. In FIG. 28, the pileremoving apparatus 2800 includes a shaft module 2802, cutting module2804, and drilling module 2806. Like the embodiment shown in FIG. 27,the pile removing apparatus 2800 includes an inner shield 2810 that isstabilized by stabilization arms 2808. The stabilization arms 2808 areconnected to an inner surface of the shaft module 2802. Also like theembodiment shown in FIG. 27, the cutting module 2804 includes clamps2814 and hydraulic cylinders 2812.

FIG. 29 shows a perspective view of a clamping mechanism, according someembodiments of the inventive subject matter. In FIG. 29, a clampingmechanism 2900 includes a clamp 2904, clamp support 2902, and clamphydraulic cylinder 2906. The clamping mechanism 2900 may be used in someembodiments, such as those shown in FIGS. 27-28. In some embodiments,the clamp support 2902 is anchored to a pivot ring of a cutting module.In other embodiments, the clamps support 2902 may be anchored to anysuitable surface. The clamp 2904 may be connected to the clamp support2902 via a clamp pin 2908, or other suitable means for coupling theclamp 2904 to the clamp support 2902. The clamp 2904 is configured torotate about the clamp pin 2908. A clamp hydraulic cylinder 2906 isconfigured to exert a force on the clamp 2904, rotating the clamp 2904about the pin 2908 and into contact with a pile.

General

This description describes numerous details about embodiments of theinvention. However, some embodiments may be practiced without thesespecific details. In some instances, for sake of clarity, thisdescription omits well-known circuits, structures and techniques. Inthis description, references to “one embodiment” or “an embodiment” meanthat a feature is included in at least one embodiment of the invention.Furthermore, separate references to “one embodiment” do not necessarilyrefer to the same embodiment. Thus, the present invention can includeany combination the embodiments described herein.

1. An apparatus for cutting a pile, the apparatus comprising: a shaftmodule including a cylindrical shaft including a first cavity configuredto receive the pile; a cutting module coupled to the shaft module, thecutting module including a second cavity configured to receive the pile;a saw configured to cut the pile; a drilling module coupled to thecutting module, the drilling module including blades to burrow into anearth surface.
 2. The apparatus of claim 1, wherein the cutting moduleincludes clamps to clamp onto the pile.
 3. The apparatus of claim 1,wherein the blades are helically shaped, and wherein the blades aremounted on an external surface of the drilling module.
 4. The apparatusof claim 1, wherein the shaft module is configured to couple to a drivemechanism configured to provide a rotational force for rotating theapparatus.
 5. The apparatus of claim 4, wherein the rotational force tocause the blades to burrow into the earth surface.
 6. The apparatus ofclaim 1, wherein the shaft module includes a motor configured to providea rotational force to spin the apparatus and cause the blades to burrowinto the earth surface.
 7. A method for cutting a pile lodged into aseafloor surface, the method including: lowering a pile cuttingapparatus around a pile, wherein the pile cutting apparatus envelops thepile; spinning the pile cutting apparatus around the pile to burrow thepile cutting apparatus into an the seafloor surface; clamping the pilecutting apparatus to the pile via clamps contained in the pile cuttingapparatus; cutting the pile using a saw included inside the pile cuttingapparatus; and lifting a portion of the pile and the pile cuttingapparatus away from the seafloor surface.
 8. The method of claim 7,wherein the portion of the pile resides at least partially below theseafloor surface.
 9. The method of claim 7, wherein the spinning resultsfrom a rotational force applied, on the pile cutting apparatus, from amotor residing on a boat.
 10. The method of claim 7, wherein thespinning results from a rotational force originating in the pile cuttingapparatus.
 11. The method of claim 7, wherein the pile cutting apparatusincludes a drilling module including helical blades configured to burrowinto the seafloor surface.
 12. The method of claim 7, the cutting isperformed by a cutting module including a saw motor, cutting wire, andpulleys configured to maintain tension in the cutting wire as thecutting wire passes through the pile.
 13. An apparatus for removing aportion of a pile that is lodged in a seafloor, the apparatus including:a drilling module configured to envelop the pile and drill into theseafloor by rotating around the pile; and a cutting module coupled tothe drilling module and configured to envelop the pile, the cuttingmodule including a saw configured to cut-off the portion of the pile.14. The apparatus of claim 13, wherein the drilling module includeshelical blades mounted on an outer surface of the drilling module. 15.The apparatus of claim 13, wherein the cutting module includes a lowerrotating ring, a middle rotating ring, and an upper rotating ring in astack, wherein each rotating ring includes a first tab, second tab, anda mobile pulley mounted on the second tab.
 16. The apparatus of claim13, wherein a saw wire rides on the mobile pulleys that are mounted onthe lower rotating ring, middle rotating ring, and upper rotating ring.16. The apparatus of claim 15, wherein rotation of the lower rotatingring causes the second tab of the lower rotating ring to engage thefirst tab of the middle rotating ring causing rotation of the middlerotating ring.
 17. The apparatus of claim 16, wherein rotation of thelower rotating ring and middle rotating ring will cause the wire saw tocut the pile.
 18. The apparatus of claim 13 further comprising a shaftmodule coupled to the cutting module, and configured to envelop thepile, the shaft module including a motor configured to apply arotational force to the drilling module to drill into the seafloor. 19.The apparatus of claim 18, wherein the motor includes a motor gearconfigured to drive spur gears, wherein the spur gears are configured todrive an internal gear configured to spin the apparatus.
 20. Theapparatus of claim 13, wherein the drilling module includes a clampconfigured to hold the apparatus fast to the pile, after drilling intothe seafloor.